Highly formable, recycled aluminum alloys and methods of making the same

ABSTRACT

Provided herein are highly formable aluminum alloys and methods of making the same. The highly formable aluminum alloys described herein can be prepared from recycled materials without significant addition of primary aluminum alloy material. The aluminum alloys are prepared by casting an aluminum alloy that can include such recycled materials and processing the resulting cast aluminum alloy article. Also described herein are methods of using the aluminum alloys and alloy products.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/518,446, filed Jul. 22, 2019, which claims priority to andfiling benefit of U.S. Provisional Patent Application No. 62/701,977,filed on Jul. 23, 2018, and U.S. Provisional Patent Application No.62/810,585, filed on Feb. 26, 2019, which are incorporated herein byreference in their entireties.

FIELD

The present disclosure relates to metallurgy generally and morespecifically to producing aluminum alloys, optionally from recycledscrap, manufacturing aluminum alloy products, and recycling aluminumalloys.

BACKGROUND

Due to the costs and time associated with producing primary aluminum,many original equipment manufacturers rely on existingaluminum-containing scrap to prepare aluminum alloy materials. However,recyclable scrap can be unsuitable for use in preparing high performancealuminum alloys, as the recyclable scrap can contain high levels ofcertain undesirable elements. For example, the recyclable scrap caninclude certain elements in amounts that affect the mechanicalproperties of the aluminum alloys, such as formability and strength.

SUMMARY

Covered embodiments of the invention are defined by the claims, not thissummary. This summary is a high-level overview of various aspects of theinvention and introduces some of the concepts that are further describedin the Detailed Description section below. This summary is not intendedto identify key or essential features of the claimed subject matter, noris it intended to be used in isolation to determine the scope of theclaimed subject matter. The subject matter should be understood byreference to appropriate portions of the entire specification, any orall drawings, and each claim.

Described herein are highly formable, recycled aluminum alloys andmethods of producing the aluminum alloys. The aluminum alloys describedherein comprise about 0.5 to 2.0 wt. % Si, 0.2 to 0.4 wt. % Fe, up to0.4 wt. % Cu, up to 0.5 wt. % Mg, 0.02 to 0.1 wt. % Mn, 0.01 to 0.1 wt.% Cr, up to 0.15 wt. % Sr, up to 0.15 wt. % total impurities, whereineach impurity is present in an amount of up to about 0.05 wt. %, and Al.In some non-limiting examples, the aluminum alloys comprise about 0.7 to1.4 wt. % Si, 0.2 to 0.3 wt. % Fe, up to 0.2 wt. % Cu, up to 0.4 wt. %Mg, 0.02 to 0.08 wt. % Mn, 0.02 to 0.05 wt. % Cr, 0.01 to 0.12 wt. % Sr,up to 0.15 wt. % impurities, and Al. In some non-limiting examples, thealuminum alloys comprise about 1.0 to 1.4 wt. % Si, 0.22 to 0.28 wt. %Fe, up to 0.15 wt. % Cu, up to 0.35 wt. % Mg, 0.02 to 0.06 wt. % Mn,0.02 to 0.04 wt. % Cr, 0.02 to 0.10 wt. % Sr, up to 0.15 wt. %impurities, and Al. Optionally, a combined content of Fe and Cr in thealuminum alloy is from about 0.22 wt. % to about 0.5 wt. %.

Also described herein are aluminum alloy products comprising thealuminum alloys as described herein. In some examples, the aluminumalloy products comprise a grain size up to about 35 μm (e.g., from about25 μm to about 35 μm or from about 28 μm to about 32 μm). Optionally,the aluminum alloy products comprise iron-containing intermetallicparticles. In some cases, at least about 36% of the iron-containingintermetallic particles can be spherical. In some non-limiting examples,at least about 36% (e.g., at least about 50% or at least about 75%) ofthe iron-containing intermetallic particles present in the aluminumalloy products have an equivalent circular diameter (i.e., “ECD”) ofabout 3 μm or less. Optionally, at least about 36% (e.g., at least about50%, at least about 70%, or at least about 80%) of the iron-containingintermetallic particles comprise α—AlFe(Mn,Cr)Si intermetallicparticles. In some cases, a volume fraction of a cube textural componentin the aluminum alloy product comprises at least about 12%. In somecases, the aluminum alloy products comprise a total elongation of atleast about 32%. The aluminum alloy product can comprise an automobilebody part, among others.

Further described herein are methods of producing an aluminum alloyproduct. The methods comprise casting an aluminum alloy as describedherein to produce a cast aluminum alloy article, homogenizing the castaluminum alloy article to produce a homogenized cast aluminum alloyarticle, hot rolling, and cold rolling the homogenized cast aluminumalloy article to produce a final gauge aluminum alloy product, andsolution heat treating the final gauge aluminum alloy product.Optionally, the homogenizing is performed at a homogenizationtemperature of from about 530° C. to about 570° C. Optionally, thealuminum alloy in the casting step comprises a recycled content in anamount of at least about 40 wt. %.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a schematic depicting a processing method as describedherein.

FIG. 1B is a schematic depicting a processing method as describedherein.

FIG. 1C is a schematic depicting a processing method as describedherein.

FIG. 2 is a graph showing the yield strength of aluminum alloys asdescribed herein.

FIG. 3 is a graph showing the ultimate tensile strength of aluminumalloys as described herein.

FIG. 4 is a graph showing the uniform elongation of aluminum alloys asdescribed herein.

FIG. 5 is a graph showing the total elongation of aluminum alloys asdescribed herein.

FIG. 6 is a graph showing the n-value (i.e., increase in strength afterdeformation) of aluminum alloys as described herein.

FIG. 7 is a graph showing the r-value (i.e., anisotropy) of aluminumalloys as described herein.

FIG. 8 is a graph showing the average r-value (i.e., anisotropy) ofaluminum alloys as described herein.

FIG. 9 is a graph showing the change in yield strength after paintbaking of aluminum alloys as described herein.

FIG. 10 is a graph showing the bendability of aluminum alloys asdescribed herein.

FIG. 11 is a graph showing the bendability of aluminum alloys asdescribed herein.

FIG. 12 is a graph showing cupping test results of aluminum alloys asdescribed herein.

FIG. 13A is a scanning electron microscope (SEM) micrograph depictingthe particle distribution of an aluminum alloy product as describedherein.

FIG. 13B is a SEM micrograph depicting the particle distribution of acomparative aluminum alloy product.

FIG. 13C is a SEM micrograph depicting the particle distribution of analuminum alloy product as described herein.

FIG. 13D is a SEM micrograph depicting the particle distribution of acomparative aluminum alloy product.

FIG. 13E is a SEM micrograph depicting the particle distribution of acomparative aluminum alloy product.

FIG. 14 is a graph showing the particle size distribution based on anequivalent circular diameter (ECD) measurement of non-sphericalparticles in an aluminum alloy as described herein.

FIG. 15 is a graph showing the particle size distribution based on anaspect ratio measurement of the particles in an aluminum alloy asdescribed herein.

FIG. 16 is a graph showing the volume fraction of iron-containingconstituent particles in aluminum alloys as described herein.

FIG. 17 is a graph showing the number density of iron-containingconstituent particles in aluminum alloys as described herein.

FIG. 18A is an optical microscope (OM) micrograph depicting the grainstructure of an aluminum alloy product as described herein.

FIG. 18B is an OM micrograph depicting the grain structure of acomparative aluminum alloy product.

FIG. 18C is an OM micrograph depicting the grain structure of analuminum alloy product as described herein.

FIG. 18D is an OM micrograph depicting the grain structure of acomparative aluminum alloy product.

FIG. 18E is an OM micrograph depicting the grain structure of acomparative aluminum alloy product.

FIG. 19 is a graph showing the average grain size of aluminum alloys asdescribed herein.

FIG. 20 is a graph showing the texture component content of aluminumalloys as described herein.

DETAILED DESCRIPTION

Provided herein are aluminum alloy products having desirable mechanicalproperties and methods of casting and processing the same. The aluminumalloy products can be recycled as well as produced from recycledmaterial (e.g., post-consumer scrap) and still exhibit desirablemechanical properties, such as good formability without cracking and/orfracture, high elongation before fracture, and good durability.

The aluminum alloy products described herein contain intermetallicparticles that have a low aspect ratio (e.g., width to height ratio). Insome cases, a low aspect ratio is a ratio of about 4 or less (e.g.,about 3 or less, about 2 or less, or about 1.5 or less). In particular,the intermetallic particles are circular or spherical in shape. Anaspect ratio of 1 (e.g., close to a circular cross section, i.e.,spherical particles) is a preferable Fe-containing intermetallicparticle shape for mechanical properties, for example bending, forming,crushing, and/or crash-testing. These intermetallic particles enhancethe desirable mechanical properties of the products and result inproducts exhibiting superior results as compared to aluminum alloyproducts having intermetallic particles that are elliptical orneedle-like in shape.

Definitions and Descriptions

As used herein, the terms “invention,” “the invention,” “this invention”and “the present invention” are intended to refer broadly to all of thesubject matter of this patent application and the claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below.

In this description, reference is made to alloys identified by aluminumindustry designations, such as “series” or “6xxx.” For an understandingof the number designation system most commonly used in naming andidentifying aluminum and its alloys, see “International AlloyDesignations and Chemical Composition Limits for Wrought Aluminum andWrought Aluminum Alloys,” or “Registration Record of AluminumAssociation Alloy Designations and Chemical Compositions Limits forAluminum Alloys in the Form of Castings and Ingot,” both published byThe Aluminum Association.

As used herein, the meaning of “a,” “an,” or “the” includes singular andplural references unless the context clearly dictates otherwise.

As used herein, a plate generally has a thickness of greater than about15 mm. For example, a plate may refer to an aluminum product having athickness of greater than about 15 mm, greater than about 20 mm, greaterthan about 25 mm, greater than about 30 mm, greater than about 35 mm,greater than about 40 mm, greater than about 45 mm, greater than about50 mm, greater than about 100 mm, or up to about 300 mm.

As used herein, a shate (also referred to as a sheet plate) generallyhas a thickness of from about 4 mm to about 15 mm. For example, a shatemay have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm,about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13mm, about 14 mm, or about 15 mm.

As used herein, a sheet generally refers to an aluminum product having athickness of less than about 4 mm. For example, a sheet may have athickness of less than about 4 mm, less than about 3 mm, less than about2 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.3mm, or less than about 0.1 mm.

Reference is made in this application to alloy temper or condition. Foran understanding of the alloy temper descriptions most commonly used,see “American National Standards (ANSI) H35 on Alloy and TemperDesignation Systems.” An F condition or temper refers to an aluminumalloy as fabricated. An O condition or temper refers to an aluminumalloy after annealing. A T1 condition or temper refers to an aluminumalloy cooled from hot working and naturally aged (e.g, at roomtemperature). A T2 condition or temper refers to an aluminum alloycooled from hot working, cold worked and naturally aged. A T3 conditionor temper refers to an aluminum alloy solution heat treated, coldworked, and naturally aged. A T4 condition or temper refers to analuminum alloy solution heat treated and naturally aged. A T5 conditionor temper refers to an aluminum alloy cooled from hot working andartificially aged (at elevated temperatures). A T6 condition or temperrefers to an aluminum alloy solution heat treated and artificially aged.A T7 condition or temper refers to an aluminum alloy solution heattreated and artificially overaged. A T8x condition or temper refers toan aluminum alloy solution heat treated, cold worked, and artificiallyaged. A T9 condition or temper refers to an aluminum alloy solution heattreated, artificially aged, and cold worked.

As used herein, the meaning of “room temperature” can include atemperature of from about 15° C. to about 30° C., for example about 15°C., about 16° C., about 17° C., about 18° C., about 19° C., about 20°C., about 21° C., about 22° C., about 23° C., about 24° C., about 25°C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30°C.

As used herein, terms such as “cast aluminum alloy article,” “cast metalarticle,” “cast article,” and the like are interchangeable and refer toa product produced by direct chill casting (including direct chillco-casting) or semi-continuous casting, continuous casting (including,for example, by use of a twin belt caster, a twin roll caster, a blockcaster, or any other continuous caster), electromagnetic casting, hottop casting, or any other casting method, or any combination thereof.

All ranges disclosed herein are to be understood to encompass anyendpoints and any and all subranges subsumed therein. For example, astated range of “1 to 10” should be considered to include any and allsubranges between (and inclusive of) the minimum value of 1 and themaximum value of 10; that is, all subranges beginning with a minimumvalue of 1 or more, e.g, 1 to 6.1, and ending with a maximum value of 10or less, e.g., 5.5 to 10.

The following aluminum alloys are described in terms of their elementalcomposition in weight percentage (wt. %) based on the total weight ofthe alloy. In certain examples of each alloy, the remainder is aluminum,with a maximum wt. % of 0.15% for the sum of the impurities.

Alloy Compositions

Described herein are novel aluminum alloys and products that exhibitdesirable mechanical properties. Among other properties, the aluminumalloys and products described herein display excellent elongation andforming properties and exceptional durability. In some cases, themechanical properties can be achieved due to the elemental compositionof the alloys. For example, the alloys described herein include iron(Fe), manganese (Mn), and chromium (Cr). The presence of at least two ofthese components, for example Fe and Mn, Fe and Cr, or Fe, Mn, and Cr,in the described amounts results in desirable intermetallic particles.As described below, an Fe content of at least about 0.50 wt. % providesan increased number of intermetallic particles during the castingprocess. In addition, other elements, such as Mn and/or Cr, influencethesize and aspect ratio of the intermetallic particles and result insmall, spherical particles having a low aspect ratio. The intermetallicparticles, in turn, serve as nucleation sites for new grains, thusresulting in an aluminum alloy product containing small, equiaxialgrains rather than coarse, elongated grains. Such aluminum alloyproducts exhibit desired forming properties. The properties displayed bythe aluminum alloy products described herein are unexpected, as a highFe content of about 0.20 wt. % and greater typically results in adecrease in formability and bendability.

In some cases, an aluminum alloy as described herein can have thefollowing elemental composition as provided in Table 1.

TABLE 1 Element Weight Percentage (wt. %) Si  0.5-2.0 Fe  0.2-0.4 Cu 0.0-0.4 Mg  0.0-0.5 Mn 0.02-0.1 Cr 0.01-0.1 Sr 0.0-0.15 Others 0-0.05(each) 0-0.15 (total) A1

In some examples, the aluminum alloy as described herein can have thefollowing elemental composition as provided in Table 2.

TABLE 2 Element Weight Percentage (wt. %) Si  0.7-1.4 Fe  0.2-0.3 Cu 0.0-0.2 Mg  0.0-0.4 Mn 0.02-0.08 Cr 0.02-0.05 Sr 0.01-0.12 Others0-0.05 (each) 0-0.15 (total) A1

In some examples, the aluminum alloy as described herein can have thefollowing elemental composition as provided in Table 3.

TABLE 3 Element Weight Percentage (wt. %) Si  1.0-1.4  Fe 0.22-0.28 Cu 0.0-0.15 Mg  0.0-0.35 Mn 0.02-0.06 Cr 0.02-0.04 Sr 0.02-0.1  Others0-0.05 (each) 0-0.15 (total) A1

In some examples, the aluminum alloy described herein includes silicon(Si) in an amount of from about 0.5% to about 2.0% (e.g., from about 0.7to about 1.5% or from about 1.0 to about 1.4%) based on the total weightof the alloy. For example, the alloy can include 0.5%, 0.51%, 0.52%,0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.6%, 0.61%, 0.62%,0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.7%, 0.71%, 0.72%,0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.8%, 0.81%, 0.82%,0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.9%, 0.91%, 0.92%,0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.01%, 1.02%,1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.1%, 1.11%, 1.12%,1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.2%, 1.21%, 1.22%,1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.3%, 1.31%, 1.32%,1.33%, 1.34%, 1.35%, 1.36%1.37%1.38%1.39%, 1.4%, 1.41%, 1.42%, 1.43%,1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, 1.5%, 1.51%, 1.52%, 1.53%,1.54%, 1.55%, 1.56%, 1.57%, 1.58%, 1.59%, 1.6%, 1.61%, 1.62%, 1.63%,1.64%, 1.65%, 1.66%, 1.67%, 1.68%, 1.69%, 1.7%, 1.71%, 1.72%, 1.73%,1.74%, 1.75%, 1.76%, 1.77%, 1.78%, 1.79%, 1.8%, 1.81%, 1.82%, 1.83%,1.84%, 1.85%, 1.86%, 1.87%, 1.88%, 1.89%, 1.9%, 1.91%, 1.92%, 1.93%,1.94%, 1.95%, 1.96%, 1.97%, 1.98%, 1.99%, or 2.0% Si. All expressed inwt. %.

In some examples, the aluminum alloy described herein includes iron (Fe)in an amount of from about 0.2% to about 0.4% (e.g., from about 0.2% toabout 0.35%, from about 0.2% to about 0.3%, from about 0.2% to about0.28%, or from about 0.22% to about 0.28%) based on the total weight ofthe alloy. For example, the alloy can include 0.2%, 0.21%, 0.22%, 0.23%,0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%,0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, or 0.4% Fe. All expressed inwt. %.

In some examples, the aluminum alloy described herein includes copper(Cu) in an amount of up to about 0.4% (e.g., from 0.0% to about 0.35% orfrom 0.0% to about 0.15%) based on the total weight of the alloy. Forexample, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%,0.07%, 0.08%, 0.09%, 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%,0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%,0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%,0.37%, 0.38%, 0.39%, or 0.4% Cu. In some cases, Cu is not present in thealloy (i.e., 0%). All expressed in wt. %.

In some examples, the aluminum alloy described herein includes magnesium(Mg) in an amount of up to about 0.5% (e.g., from 0.0% to about 0.5%,from 0.0% to about 0.4%, from 0.0% to about 0.35%, from about 0.1% toabout 0.5%, or from about 0.2% to about 0.35%) based on the total weightof the alloy. For example, the alloy can include 0.01%, 0.02%, 0.03%,0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.11%, 0.12%, 0.13%,0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%,0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%,0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%,0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, or 0.5% Mg. In some cases, Mgis not present in the alloy (i.e., 0%). All expressed in wt. %.

In some examples, the aluminum alloy described herein includes manganese(Mn) in an amount of from about 0.02% to about 0.1% (e.g., from about0.02% to about 0.08% or from about 0.02% to about 0.06%) based on thetotal weight of the alloy. For example, the alloy can include 0.02%,0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.1% Mn. Allexpressed in wt. %.

In some examples, the aluminum alloy described herein includes chromium(Cr) in an amount of from about 0.01% to about 0.1% (e.g., from about0.02 to about 0.1%, from about 0.02% to about 0.08%, or from about 0.02%to about 0.06%) based on the total weight of the alloy. For example, thealloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%,0.08%, 0.09%, or 0.1% Cr. All expressed in wt. %.

In some examples, the aluminum alloy described herein includes strontium(Sr) in an amount of up to about 0.15% (e.g., from 0.0% to about 0.15%,from about 0.02% to about 0.15%, from about 0.02% to about 0.10%, orfrom about 0.02% to about 0.14%) based on the total weight of the alloy.For example, the alloy can include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%,0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, or 0.15%Sr. In some cases, Sr is not present in the alloy (i.e., 0%). Allexpressed in wt. %. In some cases, adding Sr to the aluminum alloydescribed herein can further increase the formability and ductility ofthe material. Not to be bound by theory, the increase in formability canbe due to the eutectic modification of the intermetallic particles thatcan reduce the lamellar spacing within the eutectic component duringcasting and solidification of the aluminum alloy. Thus, Sr modificationof the eutectic component can allow the intermetallic particles to breakapart into smaller and/or finer intermetallic particles during, forexample, a hot rolling process. Finally, the finer intermetallicparticles can reduce the tendency of the aluminum alloy to undergointernal damage during deformation (e.g., forming), thereby improvingthe formability of the aluminum alloy.

Optionally, the aluminum alloy described herein can include one or bothof titanium (Ti) and zinc (Zn). In some examples, the aluminum alloydescribed herein includes Ti in an amount up to about 0.1% (e.g., fromabout 0.001% to about 0.08% or from about 0.005% to about 0.06%) basedon the total weight of the alloy. For example, the alloy can include0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%,0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.1%Ti. In some cases, Ti is not present in the alloy (i.e., 0%). In someexamples, the aluminum alloy described herein includes Zn in an amountup to about 0.1% (e.g., from about 0.001% to about 0.08% or from about0.005% to about 0.06%) based on the total weight of the alloy. Forexample, the alloy can include 0.001%, 0.002%, 0.003%, 0.004%, 0.005%,0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.02%, 0.03%, 0.04%, 0.05%,0.06%, 0.07%, 0.08%, 0.09%, or 0.1% Zn. In some cases, Zn is not presentin the alloy (i.e., 0%). All expressed in wt. %.

As described above, the presence of Fe in an amount of at least about0.2 wt. % and in combination with Cr is a factor that results in thedesirable properties exhibited by aluminum alloy products describedherein. Optionally, the combined content of Fe and Cr is at least about0.22 wt. %. In some cases, the combined content of Fe and Cr can be fromabout 0.22 wt. % to about 0.5 wt. %, from about 0.22 wt. % to about 0.4wt. %, or from about 0.25 wt. % to about 0.35 wt. %. For example, thecombined content of Fe and Cr can be 0.22%, 0.23%, 0.24%, 0.25%, 0.26%,0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%,0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%,0.47%, 0.48%, 0.49%, or 0.5%. All expressed in wt. %.

Optionally, the aluminum alloys described herein can further includeother minor elements, sometimes referred to as impurities, in amounts of0.05% or below, 0.04% or below, 0.03% or below, 0.02% or below, or 0.01%or below. These impurities may include, but are not limited to V, Ni,Sc, Hf, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof.Accordingly, V, Ni, Sc, Hf, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be presentin alloys in amounts of 0.05% or below, 0.04% or below, 0.03% or below,0.02% or below, or 0.01% or below. The sum of all impurities does notexceed 0.15% (e.g., 0.1%). All expressed in wt. %. The remainingpercentage of each alloy is aluminum.

The aluminum alloy products described herein include iron-containingintermetallic particles. In some cases, the iron-containingintermetallic particles are spherical. For example, at least about 36%of the iron-containing intermetallic particles are spherical (e.g., atleast about 40%, at least about 50%, at least about 60%, at least about70%, at least about 80%, or at least about 90% of the iron-containingintermetallic particles are spherical). At least about 36% of theparticles present in the aluminum alloy products have a particle size,measured by equivalent circular diameter (i.e., “ECD”), of about 3 μm orless (e.g., about 2.5 μm or less, about 2.0 μm or less, about 1.5 μm orless, or about 1.2 μm or less). The ECD can be determined by imposing anestimated circular cross-section on a non-spherical measured object. Forexample, the iron-containing intermetallic particles present in thealuminum alloy products can have an ECD of 3 μm or less, 2.9 μm or less,2.8 μm or less, 2.7 μm or less, 2.6 μm or less, 2.5 μm or less, 2.4 μmor less, 2.3 μm or less, 2.2 μm or less, 2.1 μm or less, 2 μm or less,1.9 μm or less, 1.8 μm or less, 1.7 μm or less, 1.6 μm or less, 1.5 μmor less, 1.4 μm or less, 1.3 μm or less, 1.2 μm or less, 1.1 μm or less,1 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm orless, 0.5 μm or less, 0.4 μm or less, 0.3 μm or less, 0.2 μm or less,0.1 μm or less, or anywhere in between. In some cases, at least 45%, atleast 50%, at least 55%, at least 60%, at least 65%, at least 70%, atleast 75%, at least 80%, at least 85%, at least 90%, at least 95%, or atleast 99% of the particles present in the aluminum alloy products havean ECD of 3 μm or less.

In some non-limiting examples, the iron-containing intermetallicparticles described herein comprise α—AlFe(Mn,Cr)Si intermetallicparticles. The α—AlFe(Mn,Cr)Si intermetallic particles can be sphericalparticles. The aluminum alloys described herein having such sphericaltype intermetallic particles are amenable to forming (e.g., bending,shaping, stamping, or any suitable forming method) when compared toaluminum alloys that predominantly include β—AlFeSi intermetallicparticles. The β—AlFeSi intermetallic particles typically have anelongated, needle-like shape. Such needle-like intermetallic particlesare detrimental to forming and thus problematic when creating aluminumalloy parts from recycled aluminum alloys.

Introducing Cr in the concentrations described above (e.g., from about0.01 wt. % to about 0.1 wt. %) into the aluminum alloy in a molten stageduring production of a primary aluminum alloy) and/or recycling (e.g.,by melting scrap aluminum alloys and optionally adding primary aluminumalloys) can allow the Cr to interact with any excess Fe found in thealuminum alloy (e.g., the molten alloy containing the primary aluminumalloy and the molten scrap) and provide the α—AlFe(Mn,Cr)Siintermetallic particles, thus replacing the β—AlFeSi intermetallicparticles. Accordingly, replacing β—AlFeSi intermetallic particles withα—AlFe(Mn,Cr)Si intermetallic particles provides aluminum alloys thatdemonstrate high formability and durability. In some cases, at leastabout 36% of the iron-containing intermetallic particles in the aluminumalloys described herein are α—AlFe(Mn,Cr)Si intermetallic particles. Forexample, at least 36%, at least 40%, at least 45%, at least 50%, atleast 55%, at least 60%, at least 65%, at least 70%, at least 75%, atleast 80%, at least 85%, at least 90%, at least 95%, or at least 99% ofthe iron-containing intermetallic particles in the aluminum alloysdescribed herein are α—AlFe(Mn,Cr)Si intermetallic particles.

In some cases, adding Cr as described herein can increase an amount ofrecycled content when providing the aluminum alloys. The aluminum alloysdescribed herein can contain at least about 40 wt. % recycled content.For example, the aluminum alloys can contain at least about 45 wt. %, atleast about 50 wt. %, at least about 60 wt. %, at least about 70 wt. %,at least about 80 wt. %, at least about 90 wt. %, or at least about 95wt. % recycled content.

In some examples, the iron-containing intermetallic particles can bepresent in the aluminum alloy in an average amount of at least about2000 to about 3000 particles per square millimeter (mm²). For example,the average amount of iron-containing intermetallic particles can beabout 2000 particles/mm², 2100 particles/mm², 2200 particles/mm², 2300particles/mm², 2400 particles/mm², 2500 particles/mm², 2600particles/mm², 2700 particles/mm², 2800 particles/mm², 2900particles/mm², 3000 particles/mm², or anywhere in between.

As described above, the intermetallic particles in the aluminum alloyscan serve as nucleation sites for grains. The aluminum alloys andproducts including the aluminum alloys can include grains having anaverage grain size of up to about 35 μm (e.g., from about 5 μm to about35 μm, from about 25 μm to about 35 μm, or from about 28 μm to about 32μm). For example, the average grain size can be about 1 μm, 5 μm, 10 μm,15 μm, 20 μm, 25 μm, 30 μm, 35 μm, or anywhere in between.

In some cases, the aluminum alloy products can have a total elongationof at least about 27% and up to about 40% when in, for example, a T4temper. For example, the aluminum alloy products can have a totalelongation of about 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%,37%, 38%, 39%, or 40%, or anywhere in between.

In some cases, the aluminum alloy products can have a uniform elongationof at least about 20% and up to about 30% when in, for example, a T4temper. For example, the aluminum alloy products can have a uniformelongation of about 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, or30%, or anywhere in between.

In some examples, the aluminum alloy products have a yield strength ofabout 100 MPa or greater when in, for example, a T4 temper. For example,the aluminum alloy products can have a yield strength of 105 MPa orgreater, 110 MPa or greater, 115 MPa or greater, 120 MPa or greater, 125MPa or greater, 130 MPa or greater, 135 MPa or greater, 140 MPa orgreater, 145 MPa or greater, or 150 MPa or greater. In some cases, theyield strength is from about 100 MPa to about 150 MPa (e.g., from about105 MPa to about 145 MPa, from about 110 MPa to about 140 MPa, or fromabout 115 MPa to about 135 MPa).

In some examples, the aluminum alloy products have an ultimate tensilestrength of about 200 MPa or greater when in, for example, a T4 temper.For example, the aluminum alloy products can have an ultimate tensilestrength of 205 MPa or greater, 210 MPa or greater, 215 MPa or greater,220 MPa or greater, 225 MPa or greater, 230 MPa or greater, 235 MPa orgreater, 240 MPa or greater, 245 MPa or greater, or 250 MPa or greater.In some cases, the ultimate tensile strength is from about 200 MPa toabout 250 MPa (e.g., from about 205 MPa to about 245 MPa, from about 210MPa to about 240 MPa, or from about 215 MPa to about 235 MPa).

The aluminum alloy products include at least a first surface portionhaving a plurality of crystallographic texture components. Thecrystallographic texture components can include recrystallizationtexture components (e.g., a Goss component, a Cube component, andRotated Cube (RC) components including an RC_(RD1) component, anRC_(RD2) component, an RC_(RN1) component, and an RC_(RN2) component).The crystallographic texture components can also include deformationtexture components (e.g., a Brass (Bs) component, an S component, aCopper component, a Shear 1 component, a Shear 2 component, a Shear 3component, a P component, a Q component, and an R component).

In some examples, the aluminum alloy products can include a Cubecomponent Optionally, a volume fraction of the Cube component in thealuminum alloy products can be at least about 12% (e.g., at least about13%, at least about 14%, at least about 15%, at least about 16%, atleast about 17%, or at least about 18%). In some examples, the volumefraction of the Cube component in the aluminum alloy products is up toabout 20% (e.g., up to about 15% or up to about 10%). For example, thevolume fraction of the Cube component in the aluminum alloy products canrange from about 12% to about 20% (e.g., from about 13% to about 20% orfrom about 16% to about 18%).

In some examples, the aluminum alloy products can include a Brasscomponent, an S component, a Copper component, and a Goss component.Optionally, a volume fraction of any one of the Brass, S, Copper, orGoss components in the aluminum alloy products can be lower than about5% (e.g., lower than about 4%, lower than about 3%, lower than about 2%,or lower than about 1%). For example, the volume fraction of any one ofthe Brass, S, Copper, or Goss components in the aluminum alloy productscan be from about 1% to about 5%, from about 1.5% to about 4.5%, or fromabout 2% to about 4%.

Methods for Preparing the Aluminum Alloys

Aluminum alloy properties are partially determined by the formation ofmicrostructures during the alloy's preparation. In certain aspects, themethod of preparation for an alloy composition may influence or evendetermine whether the alloy will have properties adequate for a desiredapplication.

Casting

The aluminum alloys as described herein can be cast into a cast aluminumalloy article using any suitable casting method. For example, thecasting process can include a direct chill (DC) casting process or acontinuous casting (CC) process. In some non-limiting examples, thealuminum alloys for use in the casting step can be a primary materialproduced from raw materials (e.g., purified aluminum and additionalalloying elements). In some further examples, the aluminum alloys foruse in the casting step can be a recycled material, produced at least inpart by aluminum scrap and optionally in combination with a primarymaterial. In some cases, aluminum alloys for use in the casting step cancontain at least about 40% of recycled content. For example, thealuminum alloy for use in the casting step can contain at least about45%, at least about 50%, at least about 60%, at least about 70%, atleast about 80%, at least about 90%, or at least about 95% of recycledcontent.

The cast aluminum alloy article can then be subjected to furtherprocessing steps. For example, the processing methods as describedherein can include the steps of homogenizing, hot rolling, cold rolling,and/or solution heat treating to form an aluminum alloy product.

Homogenization

The homogenization step as described herein was designed for thealuminum alloys described above. The aluminum alloys described hereinhave a high Si content (i.e., from 0.5 to 2.0 wt. %), which can lead tolocalized melting within the aluminum alloy matrix when homogenized attemperatures greater than about 550° C. (e.g., 560° C. and greater).Such localized melting can cause fracturing during downstream thermalprocessing steps. The homogenization step described herein is effectivein dissolving any elemental Si and concurrently avoiding localizedmelting.

The homogenization step can include heating the cast aluminum alloyarticle to attain a temperature of about, or up to about, 570° C. (e.g.,up to about 560° C., up to about 550° C., up to about 540° C., up toabout 530° C., up to about 520° C., up to about 510° C., up to about500° C., up to about 490° C., up to about 480° C., up to about 470° C.,or up to about 460° C.). For example, the cast aluminum alloy articlecan be heated to a temperature of from about 460° C. to about 570° C.(e.g., from about 465° C. to about 570° C., from about 470° C. to about570° C., from about 480° C. to about 570° C., from about 490° C. toabout 570° C., from about 500° C. to about 570° C., from about 510° C.to about 570° C., from about 520° C. to about 570° C., from about 530°C. to about 570° C., from about 540° C. to about 570° C., or from about550° C. to about 570° C.). In some cases, the heating rate can be about100° C./hour or less, 75° C./hour or less, 50° C./hour or less, 40°C./hour or less, 30° C./hour or less, 25° C./hour or less, 20° C./houror less, or 15° C./hour or less. In other cases, the heating rate can befrom about 10° C./min to about 100° C./min (e.g., from about 10° C./minto about 90° C./min, from about 10° C./min to about 70° C./min, fromabout 10° C./min to about 60° C./min, from about 20° C./min to about 90°C./min, from about 30° C./min to about 80° C./min, from about 40° C./minto about 70° C./min, or from about 50° C./min to about 60° C./min).

The cast aluminum alloy article is then allowed to soak for a period oftime. According to one non-limiting example, the cast aluminum alloyarticle is allowed to soak for up to about 15 hours (e.g., from about 20minutes to about 15 hours or from about 5 hours to about 10 hours,inclusively). For example, the cast aluminum alloy article can be soakedat a temperature of from about 500° C. to about 550° C. for about 20minutes, about 30 minutes, about 45 minutes, about 1 hour, about 1.5hours, about 2 hours, about 3 hours, about 4 hours, about 5 hours, about6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours,about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15hours, or anywhere in between.

Hot Rolling

Following the homogenization step, a hot rolling step can be performed.In certain cases, the cast aluminum alloy articles are laid down andhot-rolled with an entry temperature range of about 500° C. to 560° C.(e.g., from about 510° C. to about 550° C. or from about 520° C. toabout 540° C.). The entry temperature can be, for example, about 505°C., 510° C., 515° C., 520° C., 525° C., 530° C., 535° C., 540° C., 545°C., 550° C., 555° C., 560° C., or anywhere in between. In certain cases,the hot roll exit temperature can range from about 200° C. to about 290°C. (e.g., from about 210° C. to about 280° C. or from about 220° C. toabout 270° C.). For example, the hot roll exit temperature can be about200° C., 205° C., 210° C., 215° C., 220° C., 225° C., 230° C., 235° C.,240° C., 245° C., 250° C., 255° C., 260° C., 265° C., 270° C., 275° C.,280° C., 285° C., 290° C., or anywhere in between.

In certain cases, the cast aluminum alloy article is hot rolled to anabout 4 mm to about 15 mm gauge (e.g., from about 5 mm to about 12 mmgauge), which is referred to as a hot band. For example, the castarticle can be hot rolled to a 15 mm gauge, a 14 mm gauge, a 13 mmgauge, a 12 mm gauge, a 11 mm gauge, a 10 mm gauge, a 9 mm gauge, an 8mm gauge, a 7 mm gauge, a 6 mm gauge, a 5 mm gauge, or a 4 mm gauge. Thetemper of the as-rolled hot band is referred to as F-temper.

Coil Cooling

Optionally, the hot band can be coiled into a hot band coil (i.e., anintermediate gauge aluminum alloy product coil) upon exit from the hotmill. In some examples, the hot band is coiled into a hot band coil uponexit from the hot mill resulting in F-temper. In some further examples,the hot band coil is cooled in air. The air cooling step can beperformed at a rate of about 12.5° C./hour (° C./h) to about 3600° C./h.For example, the coil cooling step can be performed at a rate of about12.5° C./h, 25° C./h, 50° C./h, 100° C./h, 200° C./h, 400° C./h, 800°C./h, 1600° C./h, 3200° C./h, 3600° C./h, or anywhere in between. Insome still further examples, the air cooled coil is stored for a periodof time. In some examples, the intermediate coils are maintained at atemperature of about 100° C. to about 350° C. (for example, about 200°C. or about 300° C.).

Cold Rolling

A cold rolling step can optionally be performed before the solution heattreating step. In certain aspects, the hot band is cold rolled to afinal gauge aluminum alloy product (e.g., a sheet). In some examples,the final gauge aluminum alloy sheet has a thickness of 4 mm or less, 3mm or less, 2 mm or less, 1 mm or less, 0.9 mm or less, 0.8 mm or less,0.7 mm or less, 0.6 mm or less, 0.5 mm or less, 0.4 mm or less, 0.3 mmor less, 0.2 mm or less, or 0.1 mm.

Optional Inter-Annealing

In some non-limiting examples, an optional inter-annealing step can beperformed during cold rolling. For example, the hot band can be coldrolled to an intermediate cold roll gauge, annealed, and subsequentlycold rolled to a final gauge. In some aspects, the optionalinter-annealing can be performed in a batch process (i.e., a batchinter-annealing step). The inter-annealing step can be performed at atemperature of from about 300° C. to about 450° C. (e.g., about 310° C.,about 320° C., about 330° C., about 340° C., about 350° C., about 360°C., about 370° C., about 380° C., about 390° C., about 400° C., about410° C., about 420° C., about 430° C., about 440° C., or about 450° C.).

Solution Heat Treating

The solution heat treating step can include heating the final gaugealuminum alloy product from room temperature to a peak metaltemperature. Optionally, the peak metal temperature can be from about530° C. to about 570° C. (e.g., from about 535° C. to about 560° C.,from about 545° C. to about 555° C., or about 540° C.). The final gaugealuminum alloy product can soak at the peak metal temperature for aperiod of time. In certain aspects, the final gauge aluminum alloyproduct is allowed to soak for up to approximately 2 minutes (e.g., fromabout 10 seconds to about 120 seconds inclusively). For example, thefinal gauge aluminum alloy product can be soaked at the temperature offrom about 530° C. to about 570° C. for 10 seconds, 15 seconds, 20seconds, 25 seconds, 30 seconds, 35 seconds, 40 seconds, 45 seconds, 50seconds, 55 seconds, 60 seconds, 65 seconds, 70 seconds, 75 seconds, 80seconds, 85 seconds, 90 seconds, 95 seconds, 100 seconds, 105 seconds,110 seconds, 115 seconds, 120 seconds, or anywhere in between. Aftersolution heat treating, the final gauge aluminum alloy product can bequenched from the peak metal temperature at a rate of at least about 75°C. per second (° C./s). For example, the final gauge aluminum alloyproduct can be quenched at a rate of about 75° C./s, 100° C./s, 125°C./s, 150° C./s, 175° C./s, 200° C./s, or anywhere in between.

Optionally, the aluminum alloy product can then be naturally aged and/orartificially aged. In some non-limiting examples, the aluminum alloyproduct can be naturally aged to a T4 temper by storing at roomtemperature (e.g., about 15° C., about 20° C., about 25° C., or about30° C.) for at least 72 hours. For example, the aluminum alloy productcan be naturally aged for 72 hours, 84 hours, 96 hours, 108 hours, 120hours, 132 hours, 144 hours, 156 hours, 168 hours, 180 hours, 192 hours,204 hours, 216 hours, 240 hours, 264 hours, 288 hours, 312 hours, 336hours, 360 hours, 384 hours, 408 hours, 432 hours, 456 hours, 480 hours,504 hours, 528 hours, 552 hours, 576 hours, 600 hours, 624 hours, 648hours, 672 hours, or anywhere in between.

Methods of Using

The alloys and methods described herein can be used in automotive and/ortransportation applications, including motor vehicle, aircraft, andrailway applications, or any other desired application. In someexamples, the alloys and methods can be used to prepare motor vehiclebody part products, such as safety cages, bodies-in-white, crash rails,bumpers, side beams, roof beams, cross beams, pillar reinforcements(e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels,side panels, inner hoods, outer hoods, or trunk lid panels. The aluminumalloys and methods described herein can also be used in aircraft orrailway vehicle applications, to prepare, for example, external andinternal panels.

The alloys and methods described herein can also be used in electronicsapplications, to prepare, for example, external and internalencasements. For example, the alloys and methods described herein canalso be used to prepare housings for electronic devices, includingmobile phones and tablet computers. In some examples, the alloys can beused to prepare housings for the outer casing of mobile phones (e.g.,smart phones) and tablet bottom chassis.

Illustrations of Suitable Alloys, Products, and Methods

Illustration 1 is an aluminum alloy, comprising about 0.5 to 2.0 wt. %Si, 0.2 to 0.4 wt. % Fe, up to 0.4 wt. % Cu, up to 0.5 wt. % Mg, 0.02 to0.1 wt. % Mn, 0.01 to 0.1 wt. % Cr, up to 0.15 wt. % Sr, up to 0.15 wt.% impurities, and Al.

Illustration 2 is the aluminum alloy of any preceding or sub sequentillustration, comprising about 0.7 to 1.4 wt. % Si, 0.2 to 0.3 wt. % Fe,up to 0.2 wt. % Cu, up to 0.4 wt. % Mg, 0.02 to 0.08 wt. % Mn, 0.02 to0.05 wt. % Cr, 0.01 to 0.12 wt. % Sr, up to 0.15 wt. % impurities, andAl.

Illustration 3 is the aluminum alloy of any preceding or subsequentillustration, comprising about 1.0 to 1.4 wt. % Si, 0.22 to 0.28 wt. %Fe, up to 0.15 wt. % Cu, up to 0.35 wt. % Mg, 0.02 to 0.06 wt. % Mn,0.02 to 0.04 wt. % Cr, 0.02 to 0.10 wt. % Sr, up to 0.15 wt. %impurities, and Al.

Illustration 4 is the aluminum alloy of any preceding or subsequentillustration, wherein a combined content of Fe and Cr is from about 0.22wt. % to 0.50 wt. %.

Illustration 5 is an aluminum alloy product, comprising the aluminumalloy according to any preceding or subsequent illustration.

Illustration 6 is the aluminum alloy product of any preceding orsubsequent illustration, wherein the aluminum alloy product comprises agrain size of up to about 35 μm.

Illustration 7 is the aluminum alloy product of any preceding orsubsequent illustration, wherein the grain size is from about 25 μm toabout 35 μm.

Illustration 8 is the aluminum alloy product of any preceding orsubsequent illustration, comprising iron-containing intermetallicparticles.

Illustration 9 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 36% of theiron-containing intermetallic particles are spherical.

Illustration 10 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 36% of theiron-containing intermetallic particles present in the aluminum alloyproduct have an equivalent circular diameter of about 3 μm or less.

Illustration 11 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 50% of theiron-containing intermetallic particles present in the aluminum alloyproduct have an equivalent circular diameter of about 3 μm or less.

Illustration 12 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 75% of theiron-containing intermetallic particles present in the aluminum alloyproduct have an equivalent circular diameter of about 3 μm or less.

Illustration 13 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 36% of theiron-containing intermetallic particles comprise α—AlFe(Mn,Cr)Siintermetallic particles.

Illustration 14 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 50% of theiron-containing intermetallic particles comprise α—AlFe(Mn,Cr)Siintermetallic particles.

Illustration 15 is the aluminum alloy product of any preceding orsubsequent illustration, wherein at least about 80% of theiron-containing intermetallic particles comprise α—AlFe(Mn,Cr)Siintermetallic particles.

Illustration 16 is the aluminum alloy product of any preceding orsubsequent illustration, wherein a volume fraction of a cube texturalcomponent in the aluminum alloy product comprises at least about 12%.

Illustration 17 is the aluminum alloy product of any preceding orsubsequent illustration, wherein the aluminum alloy product comprises atotal elongation of at least about 32%.

Illustration 18 is the aluminum alloy product of any preceding orsubsequent illustration, wherein the aluminum alloy product comprises anautomobile body part.

Illustration 19 is a method of producing an aluminum alloy product,comprising: casting an aluminum alloy according to any preceding orsubsequent illustration to produce a cast aluminum alloy article;homogenizing the cast aluminum alloy article to produce a homogenizedcast aluminum alloy article; hot rolling and cold rolling thehomogenized cast aluminum alloy article to produce a final gaugealuminum alloy product; and solution heat treating the final gaugealuminum alloy product.

Illustration 20 is the method of any preceding or subsequentillustration, wherein the homogenizing is performed at a homogenizationtemperature of from about 530° C. to about 570° C.

Illustration 21 is the method of any preceding illustration, wherein thealuminum alloy in the casting comprises a recycled content in an amountof at least about 40 wt. %.

The following examples will serve to further illustrate the presentinvention without, however, constituting any limitation thereof. On thecontrary, it is to be clearly understood that resort may be had tovarious embodiments, modifications, and equivalents thereof which, afterreadingthe description herein, may suggest themselves to those skilledin the art without departing from the spirit of the invention.

EXAMPLES Example 1: Properties of the Aluminum Alloy Product

Aluminum alloy products were prepared having the compositions as shownin Table 4:

TABLE 4 Alloy Si Fe Cu Mn Mg Ti Zn Cr Alloy 1 1.33 0.26 0.12 0.057 0.310.017 0.006 0.025 Alloy 2 1.34 0.14 0.11 0.056 0.30 0.018 0.015 0.015Alloy 3 0.79 0.23 0.10 0.074 0.63 0.019 0.008 0.036 Alloy 4 0.62 0.230.12 0.076 0.65 0.023 0.008 0.034

In Table 4, all values are weight percent (wt. %) of the whole. Thealloys can contain up to 0.15 wt. % total impurities and the remainderis aluminum. Alloy 1 is a highly recyclable aluminum alloy as describedherein, containing 0.26 wt. % Fe and 0.025 wt. % Cr. Alloy 2, Alloy 3,and Alloy 4 are comparative 6xxx series aluminum alloys.

Alloy 1 and Alloy 2 were each processed by a method without a batchinter-annealing step (referred to herein as “no BA”), with a batchinter-annealing step (referred to herein as “BA”), and by a process witha coil cooling step (referred to herein as “CC”). FIG. 1A is a schematicdepicting a processing method 100 employed herein. Alloy 1 and Alloy 2were direct chill cast to provide an ingot 110. The ingot 110 wassubjected to a homogenization step as described above. The ingot 110 wasthen subjected to hot rolling in a reversing mill to break down theingot 110. After break down, the ingot 110 was further subjected to hotrolling in a tandem mill to provide an intermediate gauge aluminum alloyproduct. The intermediate gauge aluminum alloy product was furthersubjected to cold rolling in a cold mill to provide a final gaugealuminum alloy product.

FIG. 1B is a schematic depicting a second processing method 150including a batch inter-annealing step employed herein. Alloy 1 andAlloy 2 were each direct chill cast to provide an ingot 110. The ingot110 was subjected to a homogenization step as described above. The ingot110 was then subjected to hot rolling in a reversing mill to break downthe ingot 110. After break down, the ingot 110 was further subjected tohot rolling in a tandem mill to provide an intermediate gauge aluminumalloy product. The intermediate gauge aluminum alloy product was furthersubjected to cold rolling in a cold mill. Alloy 1 and Alloy 2 werecoiled and annealed in a furnace in a batch inter-annealing step asdescribed above. After batch inter-annealing, Alloy 1 and Alloy 2 werefurther cold rolled to the final gauge.

FIG. 1C is a schematic depicting a third processing method 175 employedherein. Alloy 3 and Alloy 4 were each direct chill cast to provide aningot 110. The ingot 110 was subjected to a homogenization step asdescribed above. The ingot 110 was then subjected to hot rolling in areversing mill to break down the ingot 110. After break down, the ingot110 was further subjected to hot rolling in a tandem mill to provide anintermediate gauge aluminum alloy product. After hot rolling, theintermediate gauge aluminum alloy product was coiled and the aluminumalloy intermediate gauge product coil was allowed to cool to roomtemperature. The intermediate gauge aluminum alloy product was furthersubjected to cold rolling in a cold mill to provide a final gaugealuminum alloy product.

FIG. 2 is a graph showing the yield strengths of test samples taken fromAlloy 1, Alloy 2, Alloy 3, and Alloy 4. Tensile properties wereevaluated in three directions including longitudinal (referred to as“L”), transverse (referred to as “T”), and diagonal (referred to as“D”), all with respect to the rolling direction during processing. Alloy1 and Alloy 2 were processed according to the processing method of FIG.1A without a batch inter-annealing step during cold rolling (“no BA”)and also according to the processing method of FIG. 1B including thebatch inter-annealing step during cold rolling (“BA”) to provide Alloy 1and Alloy 2 in a T4 temper. Alloy 3 and Alloy 4 were processed via theprocessing method of FIG. 1C with a coil cooling step before coldrolling (“CC”). In FIG. 2 , the tensile properties are shown in setsbased on the direction (i.e., L, T, or D). The first histogram bar foreach set represents Alloy 1 processed without batch annealing (“Alloy 1No BA”), the second histogram bar for each set represents Alloy 2processed without batch annealing (“Alloy 2 No BA”), the third histogrambar for each set represents Alloy 1 processed with batch annealing(“Alloy 1 BA”), the fourth histogram bar for each set represents Alloy 2processed with batch annealing (“Alloy 2 BA”), the fifth histogram barfor each set represents Alloy 3 processed according to the coil coolingmethod (“Alloy 3 CC”), and the sixth histogram bar for each setrepresents Alloy 4 processed according to the coil cooling method(“Alloy 4 CC”). As shown in FIG. 2 , the yield strengths of both Alloy 1and Alloy 2 in T4 temper ranged from 105 MPa to 125 MPa irrespective oftensile test direction or processing method, demonstrating isotropictensile properties. Additionally, Alloy 1 exhibited excellent yieldstrength, thus demonstrating a recyclable, highly formable aluminumalloy having ample strength for various automotive applications (e.g.,structural parts, aesthetic parts, and/or any combination thereof).

FIG. 3 is a graph showing the ultimate tensile strength of test samplestaken from Alloy 1, Alloy 2, Alloy 3, and Alloy 4. Preparation,processing and testing were performed as in the example of FIG. 2 . InFIG. 3 , the tensile properties are shown in sets based on the direction(i.e., L, T, or D). The first histogram bar for each set representsAlloy 1 processed without batch annealing (“Alloy 1 No BA”), the secondhistogram bar for each set represents Alloy 2 processed without batchannealing (“Alloy 2 No BA”), the third histogram bar for each setrepresents Alloy 1 processed with batch annealing (“Alloy 1 BA”), thefourth histogram bar for each set represents Alloy 2 processed withbatch annealing (“Alloy 2 BA”), the fifth histogram bar for each setrepresents Alloy 3 processed according to the coil cooling method(“Alloy 3 CC”), and the sixth histogram bar for each set representsAlloy 4 processed according to the coil cooling method (“Alloy 4 CC”).As shown in FIG. 3 , Alloy 1 exhibited excellent ultimate tensilestrength, thus demonstrating a recyclable, highly formable aluminumalloy having ample strength for various automotive applications.

FIG. 4 is a graph showing the uniform elongation of test samples takenfrom Alloy 1, Alloy 2, Alloy 3, and Alloy 4. Formability properties wereevaluated in three directions including longitudinal (referred to as“L”), transverse (referred to as “T”), and diagonal (referred to as“D”), all with respect to the rolling direction during processing. Alloy1 and Alloy 2 were processed according to the methods depicted in FIGS.1A and 1B, as described above, and Alloy 3 and Alloy 4 were processedaccording to the method depicted in FIG. 1C, as described above with acoil cooling step before cold rolling (“CC”). In FIG. 4 , the tensileproperties are shown in sets based on the direction (i.e., L, T, or D).The first histogram bar for each set represents Alloy 1 processedwithout batch annealing (“Alloy 1 No BA”), the second histogram bar foreach set represents Alloy 2 processed without batch annealing (“Alloy 2No BA”), the third histogram bar for each set represents Alloy 1processed with batch annealing (“Alloy 1 BA”), the fourth histogram barfor each set represents Alloy 2 processed with batch annealing (“Alloy 2BA”), the fifth histogram bar for each set represents Alloy 3 processedaccording to the coil cooling method (“Alloy 3 CC”), and the sixthhistogram bar for each set represents Alloy 4 processed according to thecoil cooling method (“Alloy 4 CC”). As shown in FIG. 4 , Alloy 1exhibited greater elongation in each direction (L, T, and D) than Alloy2 and Alloy 4.

FIG. 5 is a graph showing the total elongation of test samples takenfrom Alloy 1, Alloy 2, Alloy 3, and Alloy 4. Alloy 1 and Alloy 2 wereprocessed according to the methods described above and depicted in FIGS.1A and 1B, respectively, and Alloy 3 and Alloy 4 were processedaccording to the method depicted in FIG. 1C, as described above, with acoil cooling step before cold rolling (“CC”). In FIG. 5 , the tensileproperties are shown in sets based on the direction (i.e., L, T, or D).The first histogram bar for each set represents Alloy 1 processedwithout batch annealing (“Alloy 1 No BA”), the second histogram bar foreach set represents Alloy 2 processed without batch annealing (“Alloy 2No BA”), the third histogram bar for each set represents Alloy 1processed with batch annealing (“Alloy 1 BA”), the fourth histogram barfor each set represents Alloy 2 processed with batch annealing (“Alloy 2BA”), the fifth histogram bar for each set represents Alloy 3 processedaccording to the coil cooling method (“Alloy 3 CC”), and the sixthhistogram bar for each set represents Alloy 4 processed according to thecoil cooling method (“Alloy 4 CC”). As shown in FIG. 5 , the totalelongations of both Alloy 1 and Alloy 2 in T4 temper were between 26-32%irrespective of the tensile test direction or processing method, showingthe isotropic properties of Alloy 1 and Alloy 2. Additionally, Alloy 1exhibited higher formability than Alloy 2 and Alloy 4, and comparableformability to Alloy 3. Thus, Alloy 1 as prepared and processed hereinis a highly formable recyclable aluminum alloy.

FIG. 6 is a graph showing n-values (i.e., increase in strength afterdeformation) for Alloy 1, Alloy 2, Alloy 3, and Alloy 4, each preparedand processed as described above. In FIG. 6 , the n-values are shown insets based on the direction (i.e., L, T, or D). The first histogram barfor each set represents Alloy 1 processed without batch annealing(“Alloy 1 No BA”), the second histogram bar for each set representsAlloy 2 processed without batch annealing (“Alloy 2 No BA”), the thirdhistogram bar for each set represents Alloy 1 processed with batchannealing (“Alloy 1 BA”), the fourth histogram bar for each setrepresents Alloy 2 processed with batch annealing (“Alloy 2 BA”), thefifth histogram bar for each set represents Alloy 3 processed accordingto the coil cooling method (“Alloy 3 CC”), and the sixth histogram barfor each set represents Alloy 4 processed according to the coil coolingmethod (“Alloy 4 CC”). As shown in FIG. 6 , Alloy 1 and Alloy 2 samplessubjected to the method of FIG. 1A without the batch inter-annealingstep exhibited higher n-values, and thus improved forming ability.Additionally, Alloy 1 exhibited isotropic properties having equivalentn-values regardless of testing direction (e.g., L, T, and D).

FIG. 7 is a graph showing r-values (i.e., anisotropy) for Alloy 1, Alloy2, Alloy 3, and Alloy 4, each prepared and processed as described above.In FIG. 7 , the r-values are shown in sets based on the direction (i.e.,L, T, or D). The first histogram bar for each set represents Alloy 1processed without batch annealing (“Alloy 1 No BA”), the secondhistogram bar for each set represents Alloy 2 processed without batchannealing (“Alloy 2 No BA”), the third histogram bar for each setrepresents Alloy 1 processed with batch annealing (“Alloy 1 BA”), thefourth histogram bar for each set represents Alloy 2 processed withbatch annealing (“Alloy 2 BA”), the fifth histogram bar for each setrepresents Alloy 3 processed according to the coil cooling method(“Alloy 3 CC”), and the sixth histogram bar for each set representsAlloy 4 processed according to the coil cooling method (“Alloy 4 CC”).As shown in the graph, Alloy 1 processed via the method of FIG. 1B(including the batch inter-annealing step) exhibited r-values greaterthan 0.5 in all three directions (e.g., longitudinal, transverse, anddiagonal.

FIG. 8 is a graph showing average r-values for Alloys 1, 2, 3, and 4.The first histogram bar represents Alloy 1 processed without batchannealing (“Alloy 1 No BA”), the second histogram bar represents Alloy 2processed without batch annealing (“Alloy 2 No BA”), the third histogrambar represents Alloy 1 processed with batch annealing (“Alloy 1 BA”),the fourth histogram bar represents Alloy 2 processed with batchannealing (“Alloy 2 BA”), the fifth histogram bar represents Alloy 3processed according to the coil cooling method (“Alloy 3 CC”), and thesixth histogram bar represents Alloy 4 processed according to the coilcooling method (“Alloy 4 CC”). As shown in FIG. 8 , Alloy 1 and Alloy 2prepared according to the process of FIG. 1B (including batchinter-annealing) provided lower r-values than alloys processed accordingto the process of FIG. 1A (without the batch inter-annealing step).Alloys 1 and 2 exhibited similar r-values regardless of processingroute.

FIG. 9 is a graph showing the change in yield strength after paintbaking for Alloy 1 and Alloy 2 prepared and processed according to themethods described above in the examples of FIG. 1A and FIG. 1B, andAlloy 3 and Alloy 4 prepared and processed according to the methodsdescribed above in the example of FIG. 1C. After processing, paintbaking was performed by applying a 2% strain and a subsequent thermaltreatment by heating to 185° C. and maintaining the sample at thistemperature for 20 minutes. In FIG. 9 , the change in yield strengthvalues are shown in sets based on the direction (i.e., L, T, or D). Thefirst histogram bar for each set represents Alloy 1 processed withoutbatch annealing (“Alloy 1 No BA”), the second histogram bar for each set(if present) represents Alloy 2 processed without batch annealing(“Alloy 2 No BA”), the third histogram bar for each set represents Alloy1 processed with batch annealing (“Alloy 1 BA”), the fourth histogrambar for each set represents Alloy 2 processed with batch annealing(“Alloy 2 BA”), the fifth histogram bar for each set represents Alloy 3processed according to the coil cooling method (“Alloy 3 CC”), and thesixth histogram bar for each set represents Alloy 4 processed accordingto the coil cooling method (“Alloy 4 CC”). As shown in FIG. 9 , theyield strength of Alloy 1 and Alloy 2 increased to 190-220 MPa byemploying the additional straining and thermal treatment. Additionally,no significant difference in paint bake response was observed betweenAlloy 1 and Alloy 2 regardless of Fe content (Alloy 1 having 0.26 wt. %Fe and Alloy 2 having 0.16 wt. % Fe). Further, Si in aluminum alloys isknown to bind with Fe to form more Fe—constituent particles and reducethe paint bake response, which is not shown in Alloy 1.

FIG. 10 is a graph showingthe bendability of Alloy 1 and Alloy 2prepared and processed according to the process of FIG. 1A and subjectedto the VDA 238-100 three-point bend test Prior to bend testing, Alloy 1and Alloy 2 were subjected to a 10% strain in the transverse direction.As shown in the graph, Alloy 1 and Alloy 2, having significantlydifferent Fe content, exhibited similar bendability. An increase in Fecontent can adversely affect formability (e.g, bending); however, due toadded Cr, Fe-containing intermetallic particles exhibited a lower aspectratio and reduced average equivalent circular diameter, providingexcellent formability.

FIG. 11 is a graph showingthe bendability of Alloy 1 and Alloy 2prepared and processed according to the process of FIG. 1B, and Alloy 4prepared and processed according to the process of FIG. 1C, all three ofwhich were subjected to the VDA 238-100 three-point bend test. Prior tobend testing, Alloy 1, Alloy 2, and Alloy 4 were subjected to a 15%strain in the transverse direction. The first histogram bar representsAlloy 1 processed with batch annealing (“Alloy 1 BA”), the secondhistogram bar represents Alloy 2 processed with batch annealing (“Alloy2 BA”), and the third histogram bar represents Alloy 4 processedaccording to the coil cooling method (“Alloy 4 CC”). As shown in thegraph, Alloy 1 and Alloy 2, having significantly different Fe content,exhibited similar bendability. Also, Alloy 1 and Alloy 2 exhibitedgreater bendability than Alloy 4.

FIG. 12 is a graph showing the deep drawability of Alloy 1 and Alloy 2subjected to an Erichsen cupping test (DIN EN ISO 20482). As shown inthe graph, Alloy 1 and Alloy 2, having a significantly different Fecontent, exhibited similar drawability. An increase in Fe content canadversely affect formability (e.g., bending); however, due to added Cr,Fe-containing intermetallic particles exhibited a lower aspect ratio andreduced average equivalent circular diameter, providing excellentdrawability.

FIG. 13A is a SEM micrograph showing that Alloy 1 processed according tothe process of FIG. 1A, as described herein, results in iron-containing(Fe-containing) intermetallic particles having the desired shape anddistribution. As shown in the micrograph, the aluminum alloy product asdescribed herein had few β—AlFeSi intermetallic particles and displayedspherical Fe-containing intermetallic particles, includingα—AlFe(Mn,Cr)Si intermetallic particles. FIG. 13B is a SEM micrographshowingthat Alloy 2 processed accordingto the process of FIG. 1A resultsin iron-containing (Fe-containing) intermetallic particles having anincreased amount of the needle-like shaped β—AlFeSi intermetallicparticles. Alloy 2 provided an aluminum alloy product having an amountof β—AlFeSi intermetallic particles that is detrimental to the formingproperties of the aluminum alloy.

FIG. 13C is a SEM micrograph showing that Alloy 1 processed according tothe process of FIG. 1B, as described herein, resulted in smalleriron-containing (Fe-containing) intermetallic particles compared toAlloy 1 processed according to the process of FIG. 1A (see FIG. 13A).FIG. 13D is a SEM micrograph showing that Alloy 2 processed according tothe process of FIG. 1B also resulted in smaller iron-containing(Fe-containing) intermetallic particles compared to Alloy 2 processedaccording to the process of FIG. 1B (see FIG. 13B). FIG. 13E is a SEMmicrograph showing that Alloy 3 processed according to the process ofFIG. 1C exhibited more and larger Fe-containing intermetallic particles.

FIGS. 14 and 15 are graphs showing Fe-containing intermetallic particlesize distribution and aspect ratio, respectively. As shown in FIG. 14 ,Alloy 1 and Alloy 2 exhibited similar Fe-containing intermetallicparticle average size and size distribution. In FIG. 15 , Alloy 1 andAlloy 2 exhibited similar Fe-containing intermetallic particle aspectratio. By adding Cr, Fe-containing intermetallic particles exhibited alower aspect ratio and reduced average equivalent circular diameter byforming α—AlFe(Mn,Cr)Si intermetallic particles during processing. Alloy3 exhibited smaller particle sizes and aspect ratios than Alloy 1 andAlloy 2, attributed to the lower Si content (e.g., 0.79 wt. % Si).

FIGS. 16 and 17 are graphs showing the Fe-containing intermetallicparticle concentration distribution of β—AlFeSi intermetallic particles(labelled as “β”) and α—AlFe(Mn,Cr)Si intermetallic particles (labelledas “a”). In FIGS. 16 and 17 , the first histogram bar for each setrepresents Alloy 1 processed without batch annealing (“Alloy 1 No BA”),the second histogram bar for each set represents Alloy 2 processedwithout batch annealing (“Alloy 2 No BA”), the third histogram bar foreach set represents Alloy 1 processed with batch annealing (“Alloy 1BA”), the fourth histogram bar for each set represents Alloy 2 processedwith batch annealing (“Alloy 2 BA”), and the fifth histogram bar foreach set represents Alloy 3 processed according to the coil coolingmethod (“Alloy 3 CC”). As shown in FIG. 16 , Alloy 1 exhibited a greatervolume fraction of α—AlFe(Mn,Cr)Si intermetallic particles compared toAlloy 2. Similarly, as shown in FIG. 17 , Alloy 1 exhibited a greaternumber density of α—AlFe(Mn,Cr)Si intermetallic particles compared toAlloy 2. By adding Cr, Fe-containing intermetallic particles exhibited agreater formation of α—AlFe(Mn,Cr)Si intermetallic particles thanβ—AlFeSi intermetallic particles during processing. Additionally, Alloy3 exhibited a smaller area fraction and number density of Fe-containingintermetallic particles than Alloy 1.

FIG. 18A is an OM micrograph showing that Alloy 1 processed according tothe process of FIG. 1A, as described herein, results in an elongatedgrain structure. FIG. 18B is an OM micrograph showing that Alloy 2processed according to the process of FIG. 1A results in an elongatedgrain structure. FIG. 18C is an OM micrograph showing that Alloy 1processed according to the process of FIG. 1B, as described herein,results in an equiaxed grain structure. FIG. 18D is an OM micrographshowing that Alloy 2 processed according to the process of FIG. 1B alsoresults in an equiaxed grain structure. FIG. 18E is an OM micrographshowing that Alloy 3 processed according to the process of FIG. 1Cexhibited a finer, equiaxed grain structure.

FIG. 19 is a graph showing grain size distribution in Alloy 1 and Alloy2, both processed with (FIG. 1B) and without (FIG. 1A) a batchinter-annealing step, as well as Alloy 3 processed with a coil coolingstep (FIG. 1C). In FIG. 19 , the first histogram bar represents Alloy 1processed without batch annealing (“Alloy 1 No BA”), the secondhistogram bar represents Alloy 2 processed without batch annealing(“Alloy 2 No BA”), the third histogram bar represents Alloy 1 processedwith batch annealing (“Alloy 1 BA”), the fourth histogram bar representsAlloy 2 processed with batch annealing (“Alloy 2 BA”), and the fifthhistogram bar represents Alloy 3 processed according to the coil coolingmethod (“Alloy 3 CC”). As shown in FIG. 19 , the average grain size inAlloy 1 was from about 28-32 μm, regardless of the processing route.Alloy 2 exhibited a larger grain size when subjected to the batchinter-annealing step. Alloy 3 exhibited a smaller as compared to Alloy 1and Alloy 2.

FIG. 20 is a graph showing the distribution of texture components inAlloy 1 and Alloy 2 processed with and without a batch inter-annealingstep. The texture components included Brass (“bs”), S (“s”), Copper(“cu”), Goss, and Cube. In FIG. 20 , the first histogram bar for eachset represents Alloy 1 processed without batch annealing (“Alloy 1 NoBA”), the second histogram bar for each set represents Alloy 2 processedwithout batch annealing (“Alloy 2 No BA”), the third histogram bar foreach set represents Alloy 1 processed with batch annealing (“Alloy 1BA”), and the fourth histogram bar for each set represents Alloy 2processed with batch annealing (“Alloy 2 BA”). Alloy 1 exhibited agreater amount of the cube textural component (e.g., 16-18%) as comparedto Alloy 2 (e.g., 13-15%). Samples processed without the batchinter-annealing step exhibited a greater amount of the Goss texturalcomponent as compared to samples processed including the batchinter-annealing step.

All patents, publications, and abstracts cited above are incorporatedherein by reference in their entireties. Various embodiments of theinvention have been described in fulfillment of the various objectivesof the invention. It should be recognized that these embodiments aremerely illustrative of the principles of the present invention. Numerousmodifications and adaptions thereof will be readily apparent to thoseskilled in the art without departing from the spirit and scope of thepresent invention as defined in the following claims.

What is claimed is:
 1. An aluminum alloy, comprising about 0.5 to 2.0wt. % Si, 0.2 to 0.4 wt. % Fe, up to 0.4 wt. % Cu, up to 0.5 wt. % Mg,0.02 to 0.1 wt. % Mn, 0.01 to 0.1 wt. % Cr, up to 0.15 wt. % Sr, up to0.15 wt. % impurities, and Al.
 2. The aluminum alloy of claim 1,comprising about 0.7 to 1.4 wt. % Si, 0.2 to 0.3 wt. % Fe, up to 0.2 wt.% Cu, up to 0.4 wt. % Mg, 0.02 to 0.08 wt. % Mn, 0.02 to 0.05 wt. % Cr,0.01 to 0.12 wt. % Sr, up to 0.15 wt. % impurities, and Al.
 3. Thealuminum alloy of claim 1, comprising about 1.0 to 1.4 wt. % Si, 0.22 to0.28 wt. % Fe, up to 0.15 wt. % Cu, up to 0.35 wt. % Mg, 0.02 to 0.06wt. % Mn, 0.02 to 0.04 wt. % Cr, 0.02 to 0.10 wt. % Sr, up to 0.15 wt. %impurities, and Al.
 4. The aluminum alloy of claim 1, wherein a combinedcontent of Fe and Cr is from about 0.22 wt. % to 0.5 wt. %.
 5. Analuminum alloy product, comprising an aluminum alloy comprising about0.5 to 2.0 wt. % Si, 0.2 to 0.4 wt. % Fe, up to 0.4 wt. % Cu, up to 0.5wt. % Mg, 0.02 to 0.1 wt. % Mn, 0.01 to 0.1 wt. % Cr, up to 0.15 wt. %Sr, up to 0.15 wt. % impurities, and Al, wherein a combined content ofFe and Cr is from about 0.22 wt. % to 0.5 wt. %.
 6. The aluminum alloyproduct of claim 5, wherein the aluminum alloy product comprises a grainsize of up to about 35 μm.
 7. The aluminum alloy product of claim 6,wherein the grain size is from about 25 μm to about 35 μm.
 8. Thealuminum alloy product of claim 5, comprising iron-containingintermetallic particles.
 9. The aluminum alloy product of claim 8,wherein at least about 36% of the iron-containing intermetallicparticles are spherical.
 10. The aluminum alloy product of claim 8,wherein at least about 36% of the iron-containing intermetallicparticles present in the aluminum alloy product have an equivalentcircular diameter of about 3 μm or less.
 11. The aluminum alloy productof claim 8, wherein at least about 50% of the iron-containingintermetallic particles present in the aluminum alloy product have anequivalent circular diameter of about 3 μm or less.
 12. The aluminumalloy product of claim 8, wherein at least about 75% of theiron-containing intermetallic particles present in the aluminum alloyproduct have an equivalent circular diameter of about 3 μm or less. 13.The aluminum alloy product of claim 8, wherein at least about 36% of theiron-containing intermetallic particles comprise α—AlFe(Mn,Cr)Siintermetallic particles.
 14. The aluminum alloy product of claim 8,wherein at least about 50% of the iron-containing intermetallicparticles comprise α—AlFe(Mn,Cr)Si intermetallic particles.
 15. Thealuminum alloy product of claim 8, wherein at least about 80% of theiron-containing intermetallic particles comprise α—AlFe(Mn,Cr)Siintermetallic particles.
 16. The aluminum alloy product of claim 8,wherein a volume fraction of a cube textural component in the aluminumalloy product comprises at least about 12%.
 17. The aluminum alloyproduct of claim 8, wherein the aluminum alloy product comprises a totalelongation of at least about 32%.
 18. The aluminum alloy product ofclaim 8, wherein the aluminum alloy product comprises an automobile bodypart.
 19. A method of producing an aluminum alloy product, comprising:casting the aluminum alloy of claim 1 to produce a cast aluminum alloyarticle; homogenizing the cast aluminum alloy article to produce ahomogenized cast aluminum alloy article; hot rolling and cold rollingthe homogenized cast aluminum alloy article to produce a final gaugealuminum alloy product; and solution heat treating the final gaugealuminum alloy product.
 20. The method of claim 19, wherein thehomogenizing is performed at a homogenization temperature of from about530° C. to about 570° C.